Roofing dry-in method and system

ABSTRACT

This invention relates to a process for temporarily repairing a roof structure damaged by the environment or accident in order to provide for a dry interior space. Such damage may be caused by a storm, high winds, hurricane, tornado, explosion, fire, and other like events caused by nature or man. Such a process of providing a dry interior space after such an event is commonly referred to as “drying in” the structure by way of a “dry-in” process. The invention involves placing a moisture-barrier substrate over the damaged roof portion, mechanically fastening the substrate to the underlying roof structure, and finally applying a closed-cell form barrier over the substrate and surrounding roof structure, thereby creating a temporary liquid-impermeable roof patch. This process can be used in connection with at least rubber, smooth asphalt and metal roofs.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 61/765,933, filed Feb. 18, 2013, entitled ROOFING DRY-IN METHOD & SYSTEM, incorporated herein by reference.

FIELD OF THE INVENTION

This disclosure relates to a system and process for temporarily repairing a roof structure damaged by the environment or accident in order to provide for a dry interior space.

BACKGROUND

As noted, this disclosure relates to a system and process for temporarily repairing a roof structure damaged by the environment or accident in order to provide for a dry interior space. Such damage may be caused by a storm, high winds, hurricane, tornado, explosion, fire, and other like events caused by nature or man. Such a process of providing a dry interior space after such an event is commonly referred to as “drying in” the structure by way of a “dry-in” process. This process can be used in connection with at least rubber, smooth asphalt and metal roofs.

SUMMARY OF THE INVENTION

This invention involves utilizing a specific dry-in process and spray product for such dry-in situations. In one embodiment, the preferred spray product is a foam spray product. Spray roofing foam (“SPF”), often referred to as “SPF Roofing Systems,” provides many benefits to property owners. Two important benefits are waterproofing/leak prevention and insulation value. SPF Roofing Systems also provide a leak-free monolithic seal over the roof section at issue.

The novel process provided by this invention preferably involves the following steps:

-   -   1. placing a moisture barrier or substrate over the portion of         the roof damaged or under repair;     -   2. mechanically coupling or fastening the substrate to the         underlying roof structure; and     -   3. applying a foam barrier to the dry substrate surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the figures shown herein may include dimensions. Further, some of the figures shown herein may have been created from scaled drawings or from photographs that are scalable. It is understood that such dimensions, or the relative scaling within a figure, are by way of example, and not to be construed as limiting.

FIG. 1 is a plan partial view of a damaged roof prior to being repaired by this invention.

FIG. 2 is a plan partial view of the damaged roof of FIG. 1 showing the barrier that is applied over the damaged portion of the roof prior to the foam barrier being applied.

FIG. 3 is an enlarged and isolated plan view of the barrier substrate of FIG. 2 showing the method and system by which the barrier substrate is applied over the damaged portion of the roof and secured to the underlying surface prior to the foam barrier being applied.

FIGS. 4A and 4B are plan views of suitable spacers contemplated by this invention for securing the barrier substrate to the underlying surface.

FIG. 5 is a plan partial view of the damaged roof of FIG. 1 after being repaired by this invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

The embodiments disclosed below are not intended to be exhaustive or limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may simply utilize their teachings.

In a preferred embodiment, this invention involves a utilizing a specific dry-in process and spray product for such dry-in situations. In one embodiment, the preferred spray product is a foam spray product. In another embodiment, such as where hi-sloped roofs are involved, the preferred spray product is a polyurea product. As noted, SPF Roofing Systems provide many benefits to property owners, including waterproofing/leak prevention and insulation value. Other additional benefits include superior compressive strength, lightweight, self-flashing, durable and long lasting. SPF Roofing Systems also provide a leak-free monolithic seal over the roof section at issue. A strong adhesion further provides substantial wind-uplift resistance. In certain situations where reflective roof coating is utilized, lower roof temperatures can also be achieved.

The novel process provided by this invention preferably involves the following steps:

-   -   4. placing a moisture barrier or substrate over the portion of         the roof damaged or under repair;     -   5. mechanically coupling or fastening the substrate to the         underlying roof structure; and     -   6. applying a foam barrier to the dry substrate surface.

The barrier substrate contemplated by this invention is preferably synthetic roofing underlayment, such as, for example, a TITANIUM™ brand moisture barrier (model “UDL-25 Plus” available from InterWrap, Vancouver, BC Canada). Any such synthetic roofing underlayment is preferably mold-free and stronger than felt paper commonly used in roofing applications, as well as impermeable to liquid moisture. While the mechanical fasteners penetrate the barrier, the foam acts to seal over the penetrations, seal the edges of any overlapping barrier sheets, while adding rigidity and firmness to the temporary structure. For example, a one-half inch layer of the preferred foam of this invention adds “uplift” strength of over 100 miles-per-hour wind force. No SPF product commercially available on the market as of the priority date of this application warrants against such high winds.

Another advantage of an SPF Roofing System is that the resulting surface closely fits to irregular shapes and does not require a smooth undersurface. This inventive process further results in a seamless surface (thereby avoiding the need for any tape or caulk), is chemically stable and may be applied cold (thereby avoiding the need for any torches or hot kettles for application).

One preferred SPF product employed in this novel process is a polyurethane foam preferably about no less than 2.7 pound foam, and more preferably about 3 pound foam. (The weight of a given foam refers to the weight per cubic foot of expanded foam.) Such product is a two-component, liquid-spray applied, hydrofluorocarbon (HFC) blown, rigid polyurethane foam, available in varying reactivity grades in order to be applied in a wide range of temperature conditions—winter, regular or summer. In a preferred embodiment, the SPF product is closed-cell foam in order to provide a dense moisture barrier, as compared to an “open cell” barrier that would not be sufficiently dense to provide a proper barrier. One such suitable poly foam is available from Dr. Restoration, LLC, Indianapolis, Ind. (model “DRX-ISO” polyurethane foam).

In use, an applied coating of the SPF coating will preferably be tack free in a very short period of time (preferably in about 10-30 seconds), will set up preferably in about 2-10 minutes at 70 degrees F. (depending on the film thickness and substrate temperature), and will typically be totally dry (cured) preferably in about 30 minutes or less. Such a product also preferably expands and contracts as atmospheric conditions change to ensure a tight seal on the damaged roof section. The SPF coating's ability to be applied in cooler temperatures and its rapid dry time allows it to be applied quickly before subsequent inclement weather might cause further damage.

This novel dry-in process will now be described in reference to the accompanying FIGS. 1-4. FIG. 1 shows a perspective top view of a generally flat roof surface 10 (typically commercial) where, for example, wind has caused damage by, for example, uplifting one of the single-ply roofing sheets 15, thereby generating an exposed area 20 in the roof. Area 20 now presents a deficiently covered portion of the roof that could prematurely fail. In other instances, area 20 could define an entirely open space that allows rain and debris to enter directly into the interior of the structure.

Referring now to FIG. 2, the uplifted roof sheathing piece 15 has been laid back down upon the roof in its original position (because this novel process is a temporary dry-in process, sheathing piece 15 need not be affixed back to the underlying and/or surrounding roof structure) and a barrier substrate 24 is placed over the damaged area 20 (now shown in phantom in FIG. 2). The size of the substrate 24 should be of sufficient dimensions in order to provide ample coverage of the damage area 20 and to be safely secured to surrounding or adjacent roof structure in order to provide rigidity of the substrate and final roof patch, and to reduce potential sagging of the substrate 24 in the event there is no underlying structure beneath the barrier in area 20 but rather only an open area (i.e. a “hole in the roof”) caused by the storm damage.

FIG. 3 is an enlarged view of the barrier 24 shown in isolation disposed about the damaged area 20 of the roof. Barrier 24 is secured to the underlying roof structure preferably by a series of perimeter fasteners 30 and interior fasteners 32. While this invention also contemplates the fasteners being spaced evenly about the barrier 24, to provide increased strength to endure the uplifting force caused by wind about the perimeter of barrier 24, perimeter fasteners 30 may be arranged in a tighter pattern with less distance between each fastener than interior fasteners 32. In one embodiment, the preferred distance d1 between adjacent perimeter exterior fasteners 30 is about 12 inches, while the distance d2 between adjacent interior fasteners 32 is about 24 inches (while those relative distances can vary widely).

The preferred fastener contemplated by this system is a screw combined with a spacer, washer, or grommet-like plate, to prevent the fastener from simply tearing through the barrier 24. Suitable spacers 50, 60 are shown in FIGS. 4A and 4B having a center opening 52, 62 for receiving therethrough a fastener. In use, a fastener (here, preferably a screw) is placed through the spacer opening 52, 62 and then fastened downwardly through the barrier 24 into the underlying roof structure, such that the grommet plate 50, 60 is arranged atop the barrier when the securing step is completed to facilitate securing the barrier 24 to the underlying surface. Experience has shown that a suitable plate is about 2 inches in diameter, while the invention contemplates any type of spacer, grommet, washer, or plate that suitably performs such a function.

As a next (and final) step, an operator applies the preferred SPF product by way of a pressurized spraying process known in the art. During the application process, as shown in FIG. 5, the operator applies the foam product (preferably evenly) over the barrier 24 (shown in phantom) and a short distance surrounding the outside boundary of barrier 24 to provide a moisture seal or patch 34 over the damaged roof area 20 (again, in phantom). In one embodiment, the operator applies a layer of preferably about one-half inch of the SPF product, which has been found to be sufficient to provide a temporary seal of the roof section pending permanent repair. Once applied, the foam is self-flashing, that is, the foam conforms to the underlying contour, leaving no gaps between the foam and the adjacent underlying surface.

For application of the preferred SPF products, plural component spray equipment is recommended. For the preferred poly foam, employing around 2,000 lbs. per square inch of pressure is recommended in order to achieve a suitable application. Human applicators should also wear proper safety wear.

In commercial dry-in applications, most contractors will not warrant dry-in work because of substrate moisture problems. Even in this instance, foam will not typically adhere to a wet surface because the moisture causes the foam to breakdown. The novel system provided by this invention provides a durable, moisture-tight encapsulation or seal of the damaged portion of the roof. This process forms a temporary yet superior monolithic patch of the damaged portion of the roof that protects the roof and prevents moisture from entering the structure pending permanent repair of the damaged roof. This allows the contractor to indeed warrant its dry-in work, thereby providing a substantial competitive advantage to the contractor.

While this disclosure has been described as having an exemplary design, the present disclosure may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains. 

We claim:
 1. A method of providing a temporary moisture barrier, comprising the steps of: a. placing a moisture-tight substrate over at least a portion of a surface; b. fastening the substrate to the underlying surface; and c. applying a closed-cell foam barrier to the surface, wherein said foam cures to form a moisture-tight patch to said portion of the surface.
 2. The method of claim 1, wherein the surface is a roof structure, and the portion of the surface includes a damaged portion of said roof structure.
 3. The method of claim 1, wherein the portion of the surface includes a void in the surface.
 4. The method of claim 1, wherein the substrate is a sheet impermeable to liquid.
 5. The method of claim 1, wherein fastening the substrate includes mechanically fastening the substrate to said underlying surface.
 6. The method of claim 5, wherein fastening the substrate includes inserting a portion of at least one fastener through the substrate and into the underlying surface.
 7. The method of claim 6, wherein the at least one fastener is at least one screw or nail.
 8. The method of claim 6, wherein the fastener includes an elongated body and a head at an end of the elongated body, the body and head each having a diameter, and the diameter of the head is greater than the diameter of the body.
 9. The method of claim 8, further comprising inserting at least a portion of the body of the fastener through an opening of a spacer prior to inserting a portion of the at least one fastener through the substrate and into the underlying surface.
 10. The method of claim 9, wherein the spacer opening includes a diameter, the diameter of the spacer opening being equal to or greater than the diameter of the body of said fastener, and the diameter of the spacer opening being less than the diameter of the head of said fastener.
 11. The method of claim 1, wherein the closed-cell foam barrier is applied via pressurized spraying.
 12. The method of claim 11, wherein the closed-cell foam barrier is applied via spraying under pressure at a pressure of about 2000 pounds per square inch.
 13. The method of claim 12, wherein applying the closed-cell foam barrier includes applying the closed-cell foam barrier to the substrate and to at least a portion of the underlying surface abutting or surrounding the substrate.
 14. The method of claim 13, wherein the layer of closed-cell foam barrier is about one-half inch thick.
 15. The method of claim 1, wherein applying the closed-cell foam barrier includes applying a layer of closed-cell foam barrier to the substrate and to at least a portion of the surface abutting or surrounding the substrate.
 16. A system for providing a liquid-impermeable barrier over a surface, comprising: a substrate placed on a portion of a surface, the substrate being substantially impermeable to liquid; and a closed-cell foam barrier disposed atop the substrate and atop at least a portion of the surface surrounding the substrate.
 17. The system of claim 16, further comprising at least one fastener at least partially inserted through the substrate and into the underlying surface.
 18. The system of claim 17, wherein the closed-cell foam barrier overlays the substrate, the at least one fastener, and at least a portion of the underlying surface surrounding the substrate.
 19. The system of claim 16, wherein the foam cures to form a barrier substantially impermeable to liquid.
 20. The system of claim 19, wherein the foam is applied by pressurized spraying.
 21. The system of claim 17, further comprising a plurality of fasteners, at least a portion of which are located adjacent to a perimeter of the substrate. 